preventative maintenance for mud pump made in china
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Many things go into getting the most life out of your mud pump and its components — all important to extend the usage of this vital piece of equipment on an HDD jobsite. Some of the most important key points are covered below.
The most important thing you can do is service your pump, per the manufacturer’s requirements. We get plenty of pumps in the shop for service work that look like they have been abused for years without having basic maintenance, such as regular oil changes. You wouldn’t dream of treating your personal vehicle like that, so why would you treat your pump like that.
Check the oil daily and change the oil regularly. If you find water or drilling mud contamination in the oil, change the oil as soon as possible. Failure to do so will most likely leave you a substantial bill to rebuild the gear end, which could have been avoided if proper maintenance procedures would have been followed. Water in the oil does not allow the oil to perform correctly, which will burn up your gear end. Drilling mud in your gear end will act as a lapping compound and will wear out all of the bearing surfaces in your pump. Either way it will be costly. The main reasons for having water or drilling mud in the gear end of your pump is because your pony rod packing is failing and/or you have let your liners and pistons get severely worn. Indication of this is fluid that should be contained inside the fluid end of your pump is now moving past your piston and spraying into the cradle of the pump, which forces its way past the pony rod packing. Pony rod packing is meant to keep the oil in the gear end and the liner wash fluid out of the gear end. Even with brand new packing, you can have water or drilling fluid enter the gear end if it is sprayed with sufficient force, because a piston or liner is worn out.
There is also usually a valve on the inlet of the spray bar. This valve should be closed enough so that liner wash fluid does not spray all over the top of the pump and other components.
Liner wash fluid can be comprised of different fluids, but we recommend just using clean water. In extremely cold conditions, you can use RV antifreeze. The liner wash or rod wash system is usually a closed loop type of system, consisting of a tank, a small pump and a spray bar. The pump will move fluid from the tank through the spray bar, and onto the inside of the liner to cool the liner, preventing scorching. The fluid will then collect in the bottom of the cradle of the pump and drain back down into the collection tank below the cradle and repeat the cycle. It is important to have clean fluid no matter what fluid you use. If your liners are leaking and the tank is full of drilling fluid, you will not cool the liners properly — which will just make the situation worse. There is also usually a valve on the inlet of the spray bar. This valve should be closed enough so that liner wash fluid does not spray all over the top of the pump and other components. Ensure that the water is spraying inside the liner and that any overspray is not traveling out of the pump onto the ground or onto the pony rod packing where it could be pulled into the gear end. If the fluid is spraying out of the cradle area and falling onto the ground, it won’t be long before your liner wash tank is empty. It only takes a minute without the cooling fluid being sprayed before the liners become scorched. You will then need to replace the pistons and liners, which is an avoidable costly repair. Make a point to check the liner wash fluid level several times a day.
Drilling fluid — whether pumping drilling mud, straight water or some combination of fluid — needs to be clean. Clean meaning free of solids. If you are recycling your fluid, make sure you are using a quality mud recycling system and check the solids content often throughout the day to make sure the system is doing its job. A quality mud system being run correctly should be able to keep your solids content down to one quarter of 1 percent or lower. When filling your mud recycling system, be sure to screen the fluid coming into the tanks. If it is a mud recycling system, simply make sure the fluid is going over the scalping shaker with screens in the shaker. If using some other type of tank, use an inline filter or some other method of filtering. Pumping out of creeks, rivers, lakes and ponds can introduce plenty of solids into your tanks if you are not filtering this fluid. When obtaining water out of a fire hydrant, there can be a lot of sand in the line, so don’t assume it’s clean and ensure it’s filtered before use.
Cavitation is a whole other detailed discussion, but all triplex pumps have a minimum amount of suction pressure that is required to run properly. Make sure this suction pressure is maintained at all times or your pump may cavitate. If you run a pump that is cavitating, it will shorten the life of all fluid end expendables and, in severe cases, can lead to gear end and fluid end destruction. If the pump is experiencing cavitation issues, the problem must be identified and corrected immediately.
The long and the short of it is to use clean drilling fluid and you will extend the life of your pumps expendables and downhole tooling, and keep up with your maintenance on the gear end of your pump. Avoid pump cavitation at all times. Taking a few minutes a day to inspect and maintain your pump can save you downtime and costly repair bills.
Prior check to the start of a mud pump for clear water inlet and outlet pipes, buttered front and rear bearings and a filled packing. The China mud pump should be equipped with a high-pressure water pump, which pumps water to the sealing fill with a pressure greater than that of the mud pump. As a protection to the fill, never turn off the water pump while the mud pump is in its working state. Otherwise, the sealing part is of immediate wear.
The service life of the mud pump depends on the clearance between the impeller and the guard plate. An unreasonable clearance is responsible for the vibration and the noise of the pump and the damage of overflowing parts. Therefore, when it comes to the impeller replacement, the clearance shall meet the requirements of the design drawing by adjusting screws on the rear bearing. Take the suction capacity of mud into account for the allowable suction range of the mud pump is determined by water transported.
The Construction Department shall have some professional person responsible for the maintenance and repair of the construction machinery. Regular check and maintenance of the mud pump and other machinery, such as the drilling mud pump parts, are useful for the early detection and a prompt solution.
Pay attention to the size of sediment particles, among which the large ones are prone to wear the vulnerable parts of the China mud pumpsuch as pump shells, bearings, impellers, and so on. Timely maintain the use and replace the damaged. Take advanced anti-wear measures to lengthen the service life of vulnerable parts, which can downturn the cost and up forward the efficiency. Meanwhile, keep backup vulnerable parts in stock in case of unexpected replacement needs.
Explore a wide variety of water pump made in china on Alibaba.com and enjoy exquisite deals. The machines help maintain drilling mud circulation throughout the project. There are many models and brands available, each with outstanding value. These water pump made in china are efficient, durable, and completely waterproof. They are designed to lift water and mud with efficiency without using much energy or taking a lot of space.
The primary advantage of these water pump made in china is that they can raise water from greater depths. With the fast-changing technology, purchase machines that come with the best technology for optimum results. They should be well adapted to the overall configuration of the installation to perform various operations. Hence, quality products are needed for more efficiency and enjoyment of the machines" full life expectancy.
Alibaba.com offers a wide selection of products with innovative features. The products are designed for a wide range of flow rates that differ by brand. They provide cost-effective options catering to different consumer needs. When choosing the right water pump made in china for the drilling project, consider factors such as size, shape, and machine cost. More powerful tools are needed when dealing with large projects such as agriculture or irrigation.
Alibaba.com provides a wide range of water pump made in china to suit different tastes and budgets. The site has a large assortment of products from major suppliers on the market. The products are made of durable materials to avoid corrosion and premature wear during operations. The range of products and brands on the site assures quality and good value for money.
Lake Petro provides high quality Mud Pump Parts including Mud Pump Liners, Mud Pump Fluid End Module, piston, Valve and Seat etc. With more than 10 years of experience in the oil and gas industry, we are dedicated to help and support our loyal clients with the most cost-effective and quality Liners and Pistons. We also provide mud pump price and mud pump for sale.
We offer Liners with Ceramic (Zirconia and Aluminium oxide) and Steel (Metal and Bi-metal) materials for all common brands of the mud pump and triplex mud pump.
Bi-metal liners (double metal liners) are made of forged steel shell and wear-resistant sleeve of high chromium iron. In the production process, the size accuracy should be strictly controlled, which can ensure that they can be easily and stably installed. The inner sleeve with high finish and hardness is wear-resistant, corrosion-resistant and has a long service life. The bi-metal liners are suitable for a lot of bad working conditions. Its service life is more than 800 hours.
Ceramic Liners are made of a ceramic inner sleeve and a forged steel outer shell. The service life of ceramic liners is about 4000 to 10000 hours, the minimum time is at least 2000 hours, which is a lot more than bi-metal liners. Because of the phase transformation toughen technology, the ceramic liners have the features of wear-resistance, erosion-resistance, high-pressure-resistance, high hardness and strength. Zirconia type and Alumina type are common type of ceramic sleeve. Compared with Alumina type, Zirconia type liners have better toughness properties and a much longer service life. Piston wear and water consumption for lubrication can be reduced as well.
Seal Rings for Liner packing are also important. Liner Seal Rings is designed and made with hard corner which is an integral part of seal rings and soft nitrile element rubber center. We could provide reliable liner Seal Rings for our customers could order them at the same time.
All Lake Petro liner products are interchangeable with O.E.M. products. Meanwhile, we provide customized Liners according to drawings. Our liners, also with our other mud pump spares, are supplied for use in Honghua, F-Series, Bomco, Emsco and National lines of triplex drilling pumps. Let Lake Petro be your one-stop shop for your whole fleet of pumps. Please refer to “Suitable Pump Models” Lable for more details.
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When industrial equipment breaks, the resulting problem often is not the cost of replacing that equipment but the forced downtime. A production line standing still may mean thousands of dollars lost every minute. Performing regular maintenance can help avoid unplanned downtime, but it does not guarantee that equipment will not fail.
What if the machine could indicate when one of its parts was about to fail? What if the machine could even tell you which part needed to be replaced? Unplanned downtime would be reduced considerably. Planned maintenance would be performed only when necessary rather than at fixed intervals. This is the goal of predictive maintenance: avoiding downtime by using sensor data to predict when maintenance is necessary.
At the heart of developing any predictive maintenance algorithm is sensor data, which can be used to train a classification algorithm for fault detection. Meaningful features are extracted from this data in a preprocessing step and used to train a machine learning algorithm for predictive maintenance. This algorithm is exported to simulation software such as Simulink® for verification and then deployed as code to the control unit of the machine.
A solution to this challenge is to create a digital twin of the equipment and generate sensor data for various fault conditions through simulation. This approach enables engineers to generate all sensor data needed for a predictive maintenance workflow, including tests with all possible fault combinations and faults of varying severity.
This article discusses the design of a predictive maintenance algorithm for a triplex pump using MATLAB®, Simulink, and Simscape™ (Figure 1). A digital twin of the actual pump is created in Simscape and tuned to match measured data, and machine learning is used to create the predictive maintenance algorithm. The algorithm needs only the outlet pump pressure to recognize which components or combinations of components are about to fail.
A triplex pump has three plungers driven by a crankshaft (Figure 2). The plungers are laid out so that one chamber is always discharging, making the flow smoother, reducing pressure variation, and thereby lowering material strain as compared with a single-piston pump. Typical failure conditions of such a pump are worn crankshaft bearings, leaking plunger seals, and blocked inlets.
CAD models for pumps, which are often available from the manufacturer, can be imported into Simulink and used to build a mechanical model of the pump for 3D multibody simulation. To model the dynamic behavior of the system, the pump now needs to be complemented by the hydraulic and electric elements.
Some of the parameters needed for creating a digital twin, such as bore, stroke, and shaft diameter, can be found in the manufacturer’s data sheet, but others may be missing or are specified only in terms of ranges. In this example, we need the upper and lower pressures at which the three check valves feeding the outlet will open and close. We do not have exact values for these pressures, as they depend on the temperature of the fluid transported.
The plot in Figure 3 shows that simulating the pump with rough estimates (blue line) does not sufficiently match the field data (black line). The blue line resembles the measured curve to some extent, but the differences are obviously great.
We use Simulink Design Optimization™ to automatically tune the parameter values so that the model will generate results that match the measured data. The parameters selected for optimization are found in the Check Valve Outlet block in Simscape (Figure 4). Simulink Design Optimization selects parameter values, runs a simulation, and calculates the difference between the simulated and measured curves. Based on this result, new parameter values are selected, and a new simulation is run. The gradients of the parameter values are calculated to determine the direction in which the parameter should be adjusted. Convergence is achieved quickly in this example, since only two parameters were tuned. For more complex scenarios with more parameters, it is important to use capabilities that will accelerate the tuning process.
There are various ways to add fault behavior. Many Simulink blocks have dropdown menus for typical faults such as short or open circuits. Simply changing parameter values can model effects such as friction or fading. In this example, three fault types will be considered: increased friction due to a worn bearing, a reduced passage area caused by a blocked inlet, and seal leakage at the plungers. The first two faults require the adjustment of block parameters. To model leakage, we need to add a path to the hydraulic system.
In the simulation of the pump shown at the top of Figure 6, two faults have been enabled: a blocked inlet and a seal leakage at plunger 3. These faults are indicated by the red circles. The plot in Figure 6 shows the simulation results for outlet pressure both as a continuous line (blue) and sampled with noise (yellow). The data generated by the simulation must include quantization effect noise because we need to train our fault detection algorithm with data that is as realistic as possible.
Figure 6. Top: Pump schematic showing the blocked inlet and seal leakage. Bottom: Plot of the outlet pressure simulation (blue line) and sampled with noise (yellow line).
The green box in Figure 6 indicates the normal value range for outlet pressure. There are spikes clearly leaving the normal range, indicating some fault. This plot alone would tell an engineer or operator that something is wrong with the pump, but it is still impossible to judge exactly what the fault is.
We use this simulation to generate pressure data for the pump under all possible combinations of fault conditions. Approximately 200 scenarios were created for the digital twin. Each scenario must be simulated numerous times to account for quantization effects in the sensor. Since this approach requires several thousand simulations, we want to be able to speed up the data generation process.
Another approach is to use the Fast Restart feature in Simulink, which takes advantage of the fact that many systems require a certain settling time until a steady state is achieved. With Fast Restart, this portion of the test needs to be simulated only once. All subsequent simulations will start from the point where the system has reached steady state. In the current example, the settling time would make up about 70% of the simulation time required for a single test (Figure 7). Consequently, about two-thirds of the simulation time can be saved using Fast Restart. Since Fast Restart can be configured from the MATLAB command line and from scripts, it is perfectly suited to automating the training process.
The next step is to use the simulation results to extract training data for the machine learning algorithm. Predictive Maintenance Toolbox™ provides various options for extracting training data. Since the signal we are looking at here is a periodic one, a fast Fourier transform (FFT) appears most promising. As shown in Figure 8, the result is a small number of clearly separated spikes of different magnitudes for individual faults as well as for fault combinations. This is the kind of data that a machine learning algorithm can handle very well.
The FFT results for each fault scenario are extracted to a table containing the inserted faults plus the observed signal frequencies and magnitudes. As a result, the number of parameters to consider is comparably small.
Now that all the data required for training a fault detection algorithm is available, it can be imported into Statistics and Machine Learning Toolbox™. We will use a subset of the generated data to verify the trained algorithm.
We visualize the results of the training process in Statistics and Machine Learning Toolbox. These visualizations enable us to compare the strengths and weaknesses of different algorithms and determine whether additional training data is needed. We select the trained algorithm that achieved the highest accuracy for determining the pump fault from the measured data. We import that algorithm into the digital twin for verification using seven test cases saved for this purpose (Figure 9). As the final results show, the classification algorithm is able to detect all seven scenarios securely. It is now ready for deployment on the control unit.
A real-world application of this workflow is industrial equipment that will be used across the world under widely divergent environmental conditions. Such equipment may be subject to change: A new seal or valve supplier may be selected, or the pump may be operated with various kinds of fluids or in new environments with different daily temperature ranges. All these factors affect the pressure measured by the sensor, possibly making the fault detection algorithm unreliable or even useless. The ability to quickly update the algorithm to account for new conditions is critical for using this equipment in new markets.
The workflow described here can be automated using scripts in MATLAB, and most of the work can be reused. The only step that needs to be repeated is data acquisition under conditions comparable to those the pump will face in the field.
With the latest advances in smart interconnectivity, it will even be possible for machine makers to deliver equipment to customers with provisional settings, remotely collect data under actual onsite conditions, train the fault detection algorithm, and then remotely redeploy it to the machine. This will open up new customer support opportunities, including the retraining of fault detection on equipment that has been in use for some time under site-specific conditions. The insights gathered on numerous machines will benefit both customers and manufacturers.
Predictive maintenance helps engineers determine exactly when equipment needs maintenance. It reduces downtime and prevents equipment failure by enabling maintenance to be scheduled based on actual need rather than a predetermined schedule. Often it is too costly or even impossible to create the fault conditions necessary for training a predictive maintenance algorithm on the actual machine. A solution to this challenge is to use field data from the fully working machine to tune a physical 3D model and create a digital twin. The digital twin can then be used to design a predictive maintenance detection algorithm for deployment to the controller of the actual equipment. The process can be automated, enabling quick adjustment to varying conditions, materials handled, and equipment configurations.
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